Topology Optimized Filament Spool Holder for 3D Printing Nerd Design Challenge

myminifactory

How's it going? This is my entry for the first ever 3D Printing Nerd Design Challenge. The challenge was to design a filament spool holder that works seamlessly with Joel's custom filament shelves on his YouTube Channel. My design, modeled and analyzed in Solidworks 2018, is a simple, single-piece model meant to easily slide onto the shelving units Joel created. It's designed to support up to a 5kg spool of filament without showing signs of bending. Note that not all 5kg Spools are created equal - only those with an inside hole diameter close to that of a 1kg spool will work. This design is meant for the majority of 1kg spools, which account for about 99% of what people use. My entry stands out from other designs because I focused more on modeling and analysis than features like folding or anything else. The design's features are optimized to minimize stress hotspots when a force is applied from the top. Additionally, topology optimization analysis was used to drastically reduce the overall material needed for the print while maintaining structural soundness. If you're curious about my design process, I've included a brief design report explaining the basics of how I approached this project. As for the design's appearance, I think it's not very appealing. However, I chose to keep its look because the unusual features remind me that this design, although ugly, showcases the impact that analysis can have. I'm glad I could create something that highlights the capabilities of engineers like myself. I hope you enjoy my creation!